Carpet waste composite and method for making same

ABSTRACT

A carpet waste composite and method for making the same are disclosed. In one embodiment of the method, unadulterated layers of carpet having a backing side and a tufted side are provided. An initial unfused carpet layer is made by placing two cleaned, unadulterated layers of carpet tufted side-to-tufted side with homogenous and non-adhesive, non-binding contact therebetween. Heat and pressure followed by cooling are applied to furnish an initial fused carpet layer. An iterative unfused carpet layer is created by placing two cleaned, unadulterated layers of carpet tufted side-to-tufted side with the initial fused carpet layer interposed therebetween using non-adhesive, non-binding contact. Heat and pressure followed by cooling are applied to furnish an iterative fused carpet layer. The process of adding layers may continue as required.

PRIORITY STATEMENT & CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of co-pending U.S. patent applicationSer. No. 16/528,332 entitled “Carpet Waste Composite and Method forMaking Same,” and filed on Jul. 31, 2019, in the name of Daniel R.McIntyre; which claims priority from U.S. Patent Application Ser. No.62/715,401 entitled “Carpet Waste Composite and Method for Making Same,”and filed on Aug. 7, 2018 in the name of Daniel R. McIntyre; both ofwhich are hereby incorporated, in entirety, by reference for allpurposes.

TECHNICAL FIELD OF THE INVENTION

This invention relates, in general, to composites and, in particular, tocarpet waste composites and a method for making the same that are usedin various industrial, construction, and consumer applications requiringtensile strength and resistance to environmental factors, includingultraviolet light and insects, for example.

BACKGROUND OF THE INVENTION

With increased emphasis on recycling and re-use, attention has turned toalternatives to disposing of carpet waste in landfills, whether thecarpet waste is a result of new carpet production or post-consumer use.As composites may be used in various industrial, construction, andconsumer applications requiring tensile strength and resistance toenvironmental factors, including ultraviolet light and insects, forexample, efforts are focused on diverting carpet waste from landfillsand utilizing the carpet waste in the production of composites. In fact,some studies indicate as much as 6 billion pounds of carpet waste may bedeposited in landfills in the United States each year. A need exists forcarpet waste composites with acceptable performance that may beefficiently and effectively manufactured.

SUMMARY OF THE INVENTION

It would be advantageous to achieve a carpet waste-based composite thatperforms in various industrial, construction, and consumer applications.It would also be desirable to enable a thermomechanical solution thatfurnishes an effective and efficient process for the production ofcomposites with carpet waste sourced from landfill diversion and newcarpet production. To better address one or more of these concerns, inone aspect of the invention, a carpet waste composite and method formaking the same are disclosed. In one embodiment of the method, cleaned,unadulterated layers of carpet having a backing side and a tufted sideare provided. An initial unfused carpet layer is made by placingmultiple cleaned, unadulterated layers of carpet tufted side-to-tuftedside with homogenous and non-adhesive, non-binding contact therebetween.Heat and pressure followed by cooling are applied to furnish an initial,fused carpet layer. An iterative, unfused carpet layer is created byplacing multiple cleaned, unadulterated layers of carpet tuftedside-to-tufted side with the initial, fused carpet layer interposedtherebetween using homogenous and non-adhesive, non-binding contact.Heat and pressure followed by cooling are applied to furnish aniterative, fused carpet layer. The process of adding layers may continueas required.

In other aspects of the teachings presented herein, variations in themethodology are disclosed and taught. By way of example, the layers ofcarpet may be positioned tufted side-to-backing side or backingside-to-backing side at various stages in the methodology. Differentnumbers of multiple layers of carpet, such as two, or four, or more, maybe used initially or at other stages of the methodology to create theunfused, carpet layer. In another aspect, the cleaned, unadulteratedlayers of carpet may include by weight percent, 1% to 5%, for example,of additives. By way of a further aspect, the layers of carpet mayinclude adhesive and binding contact therebetween provided by anadhesive or other binder, by weight percent, of 1% to 5%, for example.These and other aspects of the invention will be apparent from andelucidated with reference to the embodiments described hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the features and advantages of thepresent invention, reference is now made to the detailed description ofthe invention along with the accompanying figures in which correspondingnumerals in the different figures refer to corresponding parts and inwhich:

FIG. 1 is a schematic illustration depicting one embodiment of a carpetwaste composite manufactured from carpet waste, according to theteachings presented herein; and

FIG. 2 is a schematic flow chart depicting one embodiment of a methodfor making a carpet waste composite according to the teachings presentedherein.

DETAILED DESCRIPTION OF THE INVENTION

While the making and using of various embodiments of the presentinvention are discussed in detail below, it should be appreciated thatthe present invention provides many applicable inventive concepts whichcan be embodied in a wide variety of specific contexts. The specificembodiments discussed herein are merely illustrative of specific ways tomake and use the invention, and do not delimit the scope of the presentinvention.

Referring initially to FIG. 1, therein is depicted one embodiment of acarpet waste composite, which is schematically illustrated and generallydesignated 10. The carpet waste composite 10 is shown as a rectangularsupport member 12 having a body 14 with sides 16, 18, 20, 22 and ends24, 26. Although the carpet waste composite 10 is depicted as arectangular support member 12, it should be appreciated that the carpetwaste composite may take any form for various industrial, construction,and consumer applications. The carpet waste composite 10 may be used asa rail tie, a crossing tie, or in another rail application.Additionally, the carpet waste composite 10 may be utilized in variousconstruction applications needing deck supports, bridge supports, beams,and other support members. Further, it should be appreciated thatalthough the carpet waste composite 10 is depicted as having arectangular shape, the shape may vary and be engineered, shaped, andangled according to the needs of the particular application.

The carpet waste composite is manufactured from carpet waste 30, whichmay be sourced from landfill diversion or new carpet production, forexample. In one embodiment, the carpet waste 30 includes a backing side32 having a tufted side 34 extending therefrom. The backing side 32 mayinclude a primary backing fabric 36 and a secondary backing fabric 38with a binding agent 40 bonding the primary backing fabric 36 to thesecondary backing fabric 38. As depicted, the primary backing fabric 36of the backing side 32 is located in contact with the tuft side 34. Thebacking side 32 provides tuft binds for securing the tufted side 34 tothe carpet, which ensures imperviousness to moisture and resistance toedge raveling. The tufted side 34 includes face yarns 42 and offerscarpet characteristics such as durability, abrasion resistance, textureretention, stain and soil resistance, colorfastness, ease of cleaning,and color clarity, for example.

The waste carpet may be sourced from various carpets, such aspolypropylene carpets, nylon 6 carpets, nylon 6,6 carpets, and polyestercarpets, or combinations thereof, for example. The vast majority ofcarpets manufactured in the United States are tufted carpets and that ofall tufted carpets, the vast majority are manufactured withthermoplastic face yarns. Major face yarn types currently used in themanufacture of tufted carpets are nylon yarns, normally composed ofpoly(epislon-caprolactam) or poly(hexamethylene adipamide), also knownas nylon-6 and nylon 6,6, respectively; propylene polymer yarns,typically composed of propylene homopolymer; and polyester yarns,normally composed of polyethylene terephthalate. Primary backings fortufted carpets are typically woven fabrics made of synthetic yarns,although nonwoven fabrics can also be used. The most common syntheticmaterial used in primary backings is polypropylene, although polyestersalso find use in the industry. Again, it will be appreciated that thevast majority of backings for tufted carpets are manufactured fromthermoplastics. The carpet finishing operation typically involvesapplication of a latex binder (typically a filled thermoset resinemulsion) and a secondary backing. The material most typically used forcarpet back coating is styrene butadiene latex (SBR), usually acarboxylated SBR. The overwhelming majority of tufted carpet today isfinished by laminating a secondary backing fabric to the primary backingfabric with a latex.

Referring to FIG. 2, therein is depicted one embodiment of a method formaking the carpet waste composite 10. At block 50, a supply of cleaned,unadulterated layers of carpet 52, 54 are provided, which in oneembodiment includes the aforementioned waste carpet 10. Althoughcleaned, unadulterated layers of carpet 52, 54 are provided, it shouldbe appreciated that the supply of carpet may be uncleaned andadulterated. The supply of cleaned, unadulterated layers of carpet 52,54 may be the same type of carpet or different types of carpet. That is,the systems and methods presented herein may be utilized with mixedcarpet stock. The cleaned, unadulterated layer of carpet 52 includes abacking side 56 and a tufted side 58. In one implementation, the backingside 56 is not separated from the tufted side 58. That is, the carpet 52may be unseparated. Further, the cleaned, unadulterated layer of carpet52 may be unshredded and without grinding as unground. In oneembodiment, intact carpet that is unseparated, unshredded, and ungroundis utilized. The cleaned, unadulterated layer of carpet 54 includes abacking side 60 and a tufted side 62. In one implementation the backingside 60 is not separated from the tufted side 62. That is, the carpet 54may be unseparated. Further, the cleaned, unadulterated layer of carpet54 may be unshredded and without grinding as unground. As previouslymentioned, the cleaned, unadulterated layers of carpet 52, 54 may besourced from various carpets, such as aforementioned polypropylenecarpets, nylon 6 carpets, nylon 6,6 carpets, and polyester carpets, orcombinations thereof, for example. The cleaned, unadulterated layers ofcarpet 52, 54 may be carpet waste that is sourced from landfilldiversion or scraps and remainder pieces from new carpet production. Thecleaned, unadulterated layers of carpet 52, 54 may be cleaned by athorough combing and vacuuming to remove any debris. In one embodiment,during the cleaning process, additional compounds and chemicals are notadded, so that the carpet 52, 54 is unadulterated.

At block 64, an initial, unfused carpet layer 66 is created by placingcleaned, unadulterated layers of carpet 52, 54 tufted side-to-tuftedside with homogenous and non-adhesive, non-binding contact therebetween.As shown, in one implementation, no adhesive and no binder are placedbetween the cleaned, unadulterated layers of carpet 52, 54.

At block 68, heat H and pressure P are applied to the unfused carpetlayer 66 within a carrier 70 having vertically spaced plates 72, 74 at afixed height F₁. By way of example and not by way of limitation, thevertically spaced plates 72, 74 may comprise aluminum plates. Further,the heat H and pressure P operations may be executed by a heatedconveyor.

In one embodiment, the fixed height F₁ may be a distance from 80thousandths of an inch (0.20 cm) to 280 thousandths of an inch (0.71cm). Additionally, the fixed height F₁ may be a distance from 130thousandths of an inch (0.33 cm) to 230 thousandths of an inch (0.58cm). In a further embodiment, the fixed height F₁ may be 180 thousandthsof an inch (0.46 cm). The heat H applied may be between 400° F. (204°C.) and 800° F. (426° C.), in one embodiment. In another embodiment, theheat H applied may be 600° F. (315.6° C.). The pressure P applied may bea continuous physical force to hold the unfused carpet layer 66 at thefixed height F₁. In one implementation the continuous physical force maysqueeze the unfused carpet layer 66 at a fixed height.

At block 76, cooling C is applied to the unfused carpet layer 66 to forman initial, fused carpet layer 78. By way of example and not by way oflimitation, the cooling C operations may be executed by a coolingconveyor. In one embodiment, the cooling C applied may be a temperatureat 35° F. (1.7° C.) to 100° F. (37° C.). In another embodiment, thecooling C applied may be 42° F. (5.6° C.). The cooling may be appliedthermomechanically or by ambient conditions, for example.

At block 80, an iterative, unfused carpet layer 82 is created by placingcleaned, unadulterated layers of carpet 84, 86 tufted side-to-tuftedside with the initial, fused carpet layer 78 interposed therebetween.The cleaned, unadulterated layer of carpet 86 includes a backing side 92and a tufted side 94. The cleaned unadulterated layer of carpet 84includes a backing side 88 and a tufted side 92. As previouslymentioned, the cleaned, unadulterated layers of carpet 84, 86 may besourced from various carpets, such as aforementioned polypropylenecarpets, nylon 6 carpets, nylon 6,6 carpets, and polyester carpets, orcombinations thereof, for example. The cleaned, unadulterated layers ofcarpet 84, 86 may be carpet waste that is sourced from landfilldiversion or scraps and remainder pieces from new carpet production. Thecleaned, unadulterated layers of carpet 84, 86 may be cleaned by athorough combing and vacuuming to remove any debris. During the cleaningprocess, additional compounds and chemicals are not added, so that thecarpet 84, 86 is unadulterated.

At block 96, heat H and pressure P are applied to the iterative, unfusedcarpet layer 82 within the carrier 70 having the plates 72, 74 with afixed height F₂. The fixed height F₂ may be greater than the fixedheight F₁. In the illustrated embodiment, the carrier 70 in block 94 isidentical to the carrier 70 in block 68. It should be appreciated thatthe carriers may be different in other implementations. By way ofexample and not by way of limitation, the heat H and pressure Poperations may be executed by the heated conveyor as previouslydescribed.

In one embodiment, the fixed height F₂ may be a distance that is twiceF₁. That is, the fixed height F₂ may be a distance from 160 thousandthsof an inch (0.41 cm) to 560 thousandths of an inch (1.42 cm).Additionally, the fixed height F₂ may be a distance from 260 thousandthsof an inch (0.66 cm) to 460 thousandths of an inch (1.17 cm). In afurther embodiment, the fixed height F₂ may be 360 thousandths of aninch (0.91 cm). The heat H applied may be between 400° F. (204° C.) and800° F. (426° C.), in one embodiment. In another embodiment, the heat Happlied may be 600° F. (315° C.). The pressure P applied may be acontinuous physical force to hold the iterative unfused carpet layer 82at the fixed height F₂.

At block 98, cooling C is applied to the unfused carpet layer 82 to forman incremental, fused carpet layer 100. By way of example and not by wayof limitation, the cooling C operations may be executed by the coolingconveyor as previously described. In one embodiment, the cooling Capplied may be a temperature at 35° F. (1.7° C.) to 100° F. (37° C.). Inanother embodiment, the cooling C applied may be 42° F. (5.6° C.)

At block 102, a further incremental, unfused carpet layer is created byplacing cleaned, unadulterated layers of carpet 104, 106 tuftedside-to-tufted side with the incremental, fused carpet layer 100interposed therebetween. The cleaned, unadulterated layer of carpet 104includes a backing side 108 and a tufted side 110. The cleaned,unadulterated layer of carpet 106 includes a backing side 112 and atufted side 114. As previously mentioned, the cleaned, unadulteratedlayers of carpet 104, 106 may be sourced from various carpets, such asaforementioned polypropylene carpets, nylon 6 carpets, nylon 6,6carpets, and polyester carpets, or combinations thereof, for example.The cleaned, unadulterated layers of carpet 104, 106 may be carpet wastethat is sourced from landfill diversion or scraps and remainder piecesfrom new carpet production. The cleaned, unadulterated layers of carpet104, 106 may be cleaned by a thorough combing and vacuuming to removeany debris. During the cleaning process, additional compounds andchemicals are not added, so that the carpet 104, 106 is unadulterated.

At block 116, heat H and pressure P are applied to the incremental,unfused carpet layer 118 within the carrier 70 having the plates 72, 74with a fixed height F_(n), which may be F₃, in instances where a thirdlayer is being manufactured. In general, the fixed height F_(n) may begreater than the fixed height F₂ and the fixed height F₁. By way ofexample and not by way of limitation, the heat H and pressure Poperations may be executed by the heated conveyor previously describedat the heat H and pressure P conditions previously described. In oneembodiment, the fixed height F_(n) may be n times F₁. So, when n equals3, then the fixed height may be F_(n=3) may be 3 times F₁. Similarly,when n equals 4, then the fixed height may be F_(n=4) may be 4 times F₁.

At block 120, cooling C is applied to the incremental, unfused carpetlayer 118 to form a further incremental, fused carpet layer 122. By wayof example and not by way of limitation, the cooling C operations may beexecuted by the cooling conveyor previously discussed.

At decision block 126, if the carpet waste composite 10 is complete,then the methodology ends at block 124. On the other hand, if additionalincremental thickness is required, then the process returns to blocks102, 116, and 120 to incrementally add another layer and F_(n) increasesincrementally. As each layer is added, in one embodiment, the fixedheight may incrementally increase by a fixed height equal to F₁. Itshould be appreciated that variations in the methodology of FIG. 2 arewithin the teachings presented herein. By way of example, the layers ofcarpet may be positioned tufted side-to-backing side or backingside-to-backing side at various stages in the methodology. That is, thelayers of carpet may be positioned side-to-side, including tuftedside-to-tufted side, tufted side-to-backing side, backing side-to-tuftedside, or backing side-to-backing side. Further, at step 50, multiplelayers of carpet, such as four, may be used initially or at other stagesof the methodology to create the unfused carpet layer.

As mentioned, it should be appreciated that variations in themethodology of FIG. 2 are within the teachings presented herein. By wayof further example, the unadulterated layers of carpet may include, byweight percent, 1% to 5% of additives. By way of further example, thelayers of carpet may include adhesive and binding contact therebetweenprovided by an adhesive or other binder by weight percent, of 1% to 5%.

Embodiments according to the teachings presented herein will now beillustrated by reference to the following non-limiting working exampleswherein procedures and materials are solely representative of thosewhich can be employed, and are not exhaustive of those available andoperative. The following glossary enumerates the components utilized inthe Examples and Test Methods presented hereinbelow.

Blended carpet is textile floor covering including nylon carpet andpolyester carpet.

Nylon carpet is a textile floor covering including nylon 6 and nylon 6,6yarns.

Polyester carpet is textile floor covering, including polyester yarns,normally composed of polyethylene terephthalate.

EXAMPLE I

A carpet waste composite is made from a supply of cleaned, unadulteratedlayers of polyester carpet. The cleaned, unadulterated layers ofpolyester carpet were cleaned by a thorough combing and vacuuming toremove any debris. During the cleaning process, additional compounds andchemicals were not added, so that the polyester carpet is unadulterated.A composite construction material was formed with seventy-five (75)layers of the polyester carpet by initially placing two layers of thepolyester carpet tufted side-to-tufted side with homogenous andnon-adhesive, non-binding contact within the heated conveyor equipmentwith a fixed height of 70 thousandths of an inch (0.180 cm) at a heat of540° F. (282.2° C.) and pressure of 1300 psi (about 8900 kPa) for 18seconds. Cooling at 75° F. (23.9° C.) was then applied for 3 minutes.Iteratively, cleaned, unadulterated layers of carpet tufted side-tuftedside were added with non-adhesive, non-binding contact under the sameheat, pressure, and cooling process with an iterative height increase of141 thousand of inches (0.360 cm).

EXAMPLE II

A carpet waste composite is made from a supply of cleaned, unadulteratedlayers of blended carpet. The cleaned, unadulterated layers of blendedcarpet was cleaned by a thorough combing and vacuuming to remove anydebris. During the cleaning process, additional compounds and chemicalswere not added, so that the blended carpet is unadulterated. A compositeconstruction material was formed with 35 layers of the blended carpet byinitially placing two layers of the blended carpet tufted side-to-tuftedside with homogenous and non-adhesive, non-binding contact within theheated conveyor equipment with a fixed height of 70 thousandths of aninch (0.180 cm) at a heat of 540° F. (282.2° C.) and pressure of 1300psi (about 8900 kPa) for 18 seconds. Cooling at 75° F. (23.9° C.) wasthen applied for 3 minutes. Iteratively, cleaned, unadulterated layersof carpet tufted side-tufted side were added with non-adhesive,non-binding contact under the same heat, pressure, and cooling processwith an iterative height increase of 141 thousandths of an inch (0.360cm).

EXAMPLE III

A carpet waste composite is made from a supply of cleaned, unadulteratedlayers of blended carpet. The cleaned, unadulterated layers of blendedcarpet was cleaned by a thorough combing and vacuuming to remove anydebris. During the cleaning process, additional compounds and chemicalswere not added, so that the blended carpet is unadulterated. A compositeconstruction material was formed with 20 layers of the blended carpet byinitially placing two layers of the blended carpet tufted side-to-tuftedside with homogenous and non-adhesive, non-binding contact within theheated conveyor equipment with a fixed height of 70 thousandths of aninch (0.180 cm) at a heat of 540° F. (282.2° C.) and pressure of 1300psi (about 8900 kPa) for 18 seconds. Cooling at 75° F. (23.9° C.) wasthen applied for 3 minutes. Iteratively, cleaned, unadulterated layersof carpet tufted side-tufted side were added with non-adhesive,non-binding contact under the same heat, pressure, and cooling processwith an iterative height increase of 141 thousandths of an inch (0.360cm).

Test Method I. Three carpet waste composites in accordance withteachings presented herein and manufactured in conformity with each ofExample I, Example II, and Example III were tested according to thestandard test method for plastic composite cross ties prescribed in theAmerican Railway Engineering and Maintenance-of-way Association (AREMA)Guidance for Plastic Composite Cross Ties. This test method covers thedetermination of the properties of modules of elasticity, modulus ofrupture, rail seat compression, single tie lateral push, spike/screwpullout, and thermal expansion. Table I, Table II, and Table III depictthe AREMA Guidance for Plastic Composite Cross Ties test results for theEx. I, Ex. II, and Ex. III Carpet Waste Composites.

TABLE I AREMA Guidance for Plastic Composite Cross Ties Test Results forSelect Carpet Waste Composites in accordance with Example I AREMAGuidance for Plastic Composite Cross Ties (Example I) Modulus ofElasticity Min. - 170,000 psi PASSED Modulus of Rupture Min. - 2,000 psiPASSED Rail Seat Compression Min. - 900 psi PASSED Single Tie LateralPush Min. - 2,000 lbf PASSED Spike/Screw Pullout Min. - 1,900/5,000 lbfPASSED Thermal Expansion Max. - 7.5 × 10⁻⁵ in/in/° F. PASSED

TABLE II AREMA Guidance for Plastic Composite Cross Ties Test Resultsfor Select Carpet Waste Composites in accordance with Example II AREMAGuidance for Plastic Composite Cross Ties (Example II) Modulus ofElasticity Min. - 170,000 psi PASSED Modulus of Rupture Min. - 2,000 psiPASSED Rail Seat Compression Min. - 900 psi PASSED Single Tie LateralPush Min. - 2,000 lbf PASSED Spike/Screw Pullout Min. - 1,900/5,000 lbfPASSED Thermal Expansion Max. - 7.5 × 10⁻⁵ in/in/° F. PASSED

TABLE III AREMA Guidance for Plastic Composite Cross Ties Test Resultsfor Select Carpet Waste Composites in accordance with Example III AREMAGuidance for Plastic Composite Cross Ties (Example III) Modulus ofElasticity Min. - 170,000 psi PASSED Modulus of Rupture Min. - 2,000 psiPASSED Rail Seat Compression Min. - 900 psi PASSED Single Tie LateralPush Min. - 2,000 lbf PASSED Spike/Screw Pullout Min. - 1,900/5,000 lbfPASSED Thermal Expansion Max. - 7.5 × 10⁻⁵ in/in/° F. PASSED

As shown by the results of Test Method I, the Ex. I, Ex. II, and Ex. IIIcarpet waste composites exhibited passing performance under the AmericanRailway Engineering and Maintenance-of-way Association (AREMA) Guidancefor Plastic Composite Cross Ties, which examined modules of elasticity,modulus of rupture, rail seat compression, single tie lateral push,spike/screw pullout, and thermal expansion. Accordingly, the results ofTesting Method I illustrates that the carpet waste compositesmanufactured in accordance with the teachings presented herein exhibitphysical properties that are equivalent or better than those of existingplastic composite rail ties.

The order of execution or performance of the methods and stepsillustrated and described herein is not essential, unless otherwisespecified. That is, elements of the methods and steps may be performedin any order, unless otherwise specified, and that the methods mayinclude more or less elements than those disclosed herein. For example,it is contemplated that executing or performing a particular elementbefore, contemporaneously with, or after another element are allpossible sequences of execution.

While this invention has been described with reference to illustrativeembodiments, this description is not intended to be construed in alimiting sense. Various modifications and combinations of theillustrative embodiments as well as other embodiments of the invention,will be apparent to persons skilled in the art upon reference to thedescription. It is, therefore, intended that the appended claimsencompass any such modifications or embodiments.

What is claimed is:
 1. A method of manufacturing a compositeconstruction material, the method comprising: providing first, second,third, and fourth cleaned, unadulterated layers of intact carpet, eachof the first, second, third, and fourth unadulterated layers of intactcarpet having a backing side and a tufted side; creating an initialunfused carpet layer by placing the first and second cleaned,unadulterated layers of intact carpet in a side-to-side placement withhomogenous and non-adhesive, non-binding contact therebetween, theside-to-side placement includes a placement selected from the groupconsisting of tufted side-to-tufted side, tufted side-to-backing side,backing side-to-tufted side, and backing side-to-backing side; applyingfirst heat and pressure to the initial unfused carpet layer within afirst carrier having a first fixed height; applying first cooling to theinitial unfused carpet layer to form an initial fused carpet layer;creating an iterative unfused carpet layer by placing the third andfourth cleaned, unadulterated layers of intact carpet in theside-to-side placement with the initial fused carpet layer interposedtherebetween, the initial fused carpet layer forming non-adhesive,non-binding contact with each of the third and fourth cleaned,unadulterated layers of intact carpet; applying second heat and pressureto the iterative unfused carpet layer within a second carrier having asecond fixed height, the second fixed height being greater than thefirst fixed height; and applying second cooling to the iterative unfusedcarpet layer to form the iterative fused carpet layer.
 2. The method asrecited in claim 1, wherein the first unadulterated layer of intactcarpet further comprises nylon fibers.
 3. The method as recited in claim1, wherein the first unadulterated layer of intact carpet furthercomprises polyester fibers.
 4. The method as recited in claim 1, whereinthe first carrier further comprises first and second aluminum plates. 5.The method as recited in claim 1, wherein the first fixed height furthercomprises a distance from 80 thousandths of an inch (0.20 cm) to 280thousandths of an inch (0.71 cm).
 6. The method as recited in claim 1,wherein the first fixed height further comprises a distance from 130thousandths of an inch (0.33 cm) to 230 thousandths of an inch (0.58cm).
 7. The method as recited in claim 1, wherein the first fixed heightfurther comprises a distance less than 200 thousandths of an inch (0.51cm).
 8. The method as recited in claim 1, wherein the first fixed heightfurther comprises a distance of 180 thousandths of an inch (0.46 cm). 9.The method as recited in claim 1, wherein applying first heat andpressure further comprises applying heat between 400° F. (204° C.) and800° F. (426° C.)
 10. The method as recited in claim 1, wherein applyingfirst heat and pressure further comprises applying heat at 600° F. (315°C.)
 11. The method as recited in claim 1, wherein applying first heatand pressure further comprises applying a continuous physical force tohold the initial unfused carpet layer at the first fixed height.
 12. Themethod as recited in claim 1, wherein applying first cooling furthercomprises applying cooling at 35° F. (1.7° C.) to 100° F. (37° C.) 13.The method as recited in claim 1, wherein applying first cooling furthercomprises applying cooling at 42° F. (5.6° C.)
 14. The method as recitedin claim 1, wherein the second carrier and the first carrier areidentical.
 15. The method as recited in claim 1, wherein the secondcarrier further comprises first and second aluminum plates.
 16. Themethod as recited in claim 1, wherein the second fixed height is twicethe first fixed height.
 17. A method of manufacturing a compositeconstruction material, the method comprising: providing first, second,third, and fourth cleaned, unadulterated layers of intact carpet, eachof the first, second, third, and fourth unadulterated layers of intactcarpet having a backing side and a tufted side; creating an initialunfused carpet layer by placing the first and second cleaned,unadulterated layers of intact carpet in a side-to-side placement withhomogenous and non-adhesive, non-binding contact therebetween, theside-to-side placement includes a placement selected from the groupconsisting of tufted side-to-backing side, backing side-to-tufted side,and backing side-to-backing side; applying first heat and pressure tothe initial unfused carpet layer within a first carrier having a firstfixed height; applying first cooling to the initial unfused carpet layerto form an initial fused carpet layer; creating an iterative unfusedcarpet layer by placing the third and fourth cleaned, unadulteratedlayers of intact carpet in the side-to-side placement with the initialfused carpet layer interposed therebetween, the initial fused carpetlayer forming non-adhesive, non-binding contact with each of the thirdand fourth cleaned, unadulterated layers of intact carpet; applyingsecond heat and pressure to the iterative unfused carpet layer within asecond carrier having a second fixed height, the second fixed heightbeing greater than the first fixed height; and applying second coolingto the iterative unfused carpet layer to form an iterative fused carpetlayer.
 18. The method as recited in claim 17, wherein the first fixedheight further comprises a distance of 180 thousandths of an inch (0.46cm).
 19. A method of manufacturing a composite construction material,the method comprising: providing first, second, third, and fourthcleaned, unadulterated layers of intact carpet, each of the first,second, third, and fourth unadulterated layers of intact carpet having abacking side and a tufted side; creating an initial unfused carpet layerby placing the first and second cleaned, unadulterated layers of intactcarpet in a side-to-side placement with homogenous and non-adhesive,non-binding contact therebetween, the side-to-side placement includes aplacement selected from the group consisting of tufted side-to-backingside, and backing side-to-tufted side; applying first heat and pressureto the initial unfused carpet layer within a first carrier having afirst fixed height; applying first cooling to the initial unfused carpetlayer to form an initial fused carpet layer; creating an iterativeunfused carpet layer by placing the third and fourth cleaned,unadulterated layers of intact carpet in the side-to-side placement withthe initial fused carpet layer interposed therebetween, the initialfused carpet layer forming non-adhesive, non-binding contact with eachof the third and fourth cleaned, unadulterated layers of intact carpet;applying second heat and pressure to the iterative unfused carpet layerwithin a second carrier having a second fixed height, the second fixedheight being greater than the first fixed height; and applying secondcooling to the iterative unfused carpet layer to form an iterative fusedcarpet layer.
 20. The method as recited in claim 19, wherein the firstfixed height further comprises a distance of 180 thousandths of an inch(0.46 cm).